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The zeolite monoliths were synthesized by a facile polymer scaffold template assisted hydrothermal method. The selected foam-shaped template of a polyurethane (PU) foam monolith, was used to prepare the self-standing zeolite foam (ZF) monolithic materials. The obtained ZF products can preserve the same size, shape and macroporous network structure of the original PU foam scaffold template, although the zeolite nano-crystallites had been fully substituted for the PU template to form the new skeleton struts and walls. The as-synthesized ZF products demonstrated abundant hierarchical porosity (involving triple micro-, meso- and macropores). Meanwhile, compared with the conventional zeolite powders, the self-standing ZF monolithic materials exhibited greater total pore volume and nearly three times higher mesopore volume, suggesting wider applications as catalysts, catalyst supports and adsorbents in industry.

A novel Pd-loaded self-standing hierarchical pore structure silicalite were obtained by a handy polymer form board assisted hydrothermal method. The selected foam-shaped form board of a polyurethane (PU) foam monolith was regarded as the precursor of the self-standing hierarchical pore structure silicalite. The fruiting silicalite can steadily hold unique macroporous network structure and shape of the anterior original PU foam board . By means of the BET and BJH pore size distribution tests, the as-synthesis silicalite demonstrated hierarchical pore structure. The method of in-situ reduction was wielded to load palladium on the silicalite, and the catalytic performance of the catalyst to decompose toluene was tested at multiple burning temperatures. The experimental results revealed that the Pd-loaded catalyst can effectively decompose toluene at nearly 230°C, realizing low-temperature catalytic combustion of toluene.